Model Based Process Analysis And Tool Development For Sustainable Electroplating Operations

The electroplating industry has faced tremendous challenges in maintaining its economic competitiveness as well as improving its environmental performance in the global economy. In electroplating systems, waste generation from manufacturing lines has been always a serious concern, as waste emitted in different forms contains various hazardous and toxic chemicals. It is recognized that much of the generated waste is avoidable, and reduction of such avoidable waste could significantly reduce the consumption of chemicals, energy, and water. Proactive source reduction can improve not only environmental quality, but also economic performance. This type of source reduction, which could be called Proactive Pollution Prevention, can be achieved through applying advanced sustainability-bearing process systems engineering techniques, i.e., the fundamental system modeling and simulation techniques. In this thesis, the process models developed for electroplating systems are reviewed and selectively adopted. These models are embedded in a computer aided simulation tool, which is MATLAB based platform. The tool has been used to conduct comprehensive simulation of electroplating systems. It can characterize the dynamic operations of cleaning and rinsing operations, where chemicals, energy and water are consumed. This software tool helps users to analyze the process under given conditions and predict the consumption of chemicals in cleaning tanks, and rinse water consumption in rinsing tanks. The simulation facilitates identification of superior operating conditions in the electroplating systems, and it provides comparison between conventional and suggested operational strategies. This model-based simulation methodology as well as the tool should be valuable for the electroplating industry to improve their system’s sustainability performance

A detailed review on current status of energy efficiency improvement in the Swiss industry sector

While quantitative methods for tracking the evolution of energy efficiency (EE) in industry do exist, these cannot always be directly applied, mainly due to lack of data on physical activity levels, as encountered in Switzerland. Therefore, a bottom-up method is developed and tested for estimating the sectoral physical activity levels in Switzerland. On this basis, sector-specific EE indices are determined. The results show that during the period 2009–2016, EE improved most in the paper sector (3.3% p.a.), followed by minerals (2.3% p.a.) and food (1.6% p.a.) sectors while the levels have remained approximately unchanged in chemical and metal sectors. Furthermore, the annual change in final energy demand was decomposed into changes of physical production, price levels and EE. The analysis concluded that only the food sector performed well according to all performance indicators. The detailed analysis of the Swiss target agreements’ data has revealed major final energy savings in chemical and food sectors during the period 2000–2016. Among the different categories of EE measures, process related measures have proven to yield the highest energy savings across all sectors. The results indicate the successful implementation of EE measures in Swiss industry, favored by the relatively strict Swiss regulatory framework and its target agreement mechanism

Technology and Investment Options for Total Final Energy Reduction and CO₂ Abatement in the Swiss Industry

This thesis examines the contribution of energy efficiency improvement in the Swiss industry sector in attaining Switzerland's net-zero emission target. By analyzing energy consumption trends and drivers, with a specific focus on the metals and food and beverage manufacturing sub-sectors, the thesis identifies significant opportunities for short and medium-term energy efficiency improvements and decarbonization within the Swiss industry. It presents a comprehensive analysis of cost-effective measures, ranked through energy efficiency cost curves, which can lead to substantial CO2 abatement. The profitability analysis demonstrates the economic viability of energy efficiency investments for different types of industrial establishments. A case study on the chocolate industry showcases the potential of process heat electrification using heat pumps. The findings emphasize the urgency of implementing these identified energy efficiency measures to achieve short and medium-term decarbonization goals in the Swiss industry sector, contributing to a sustainable and low-carbon future

Analysis of energy efficiency improvement and carbon dioxide abatement potentials for Swiss Food and Beverage sector

The food and beverage (F&B) production is the second most energy consuming industry sector, consuming up to 14% (22 PJ) of the Swiss industry's total final energy (TFE) and emitting 14% (0.6 million tonnes) of the industry's total CO2. In the period from 2004 to 2017, the sector's energy consumption has been increasing at a faster rate than production, which implies deterioration of energy efficiency (EE). Against the background of implicit EE improvement target of 26% between 2017 and 2050 under the assumption of constant future production, this study investigates the options of realizing the target. The process-related (e.g. excluding building envelope) technical EE improvement potential of the Swiss F&B sector is estimated at 25% whereas the currently commercially available energy-efficient technologies can potentially reduce 18% of the sector's current TFE. The cost-effective potential estimated by means of a bottom-up approach (cost curves) ranges from 14% to 16% for energy efficiency and 18% to 21% for CO2. Results of sensitivity analysis indicate that low energy prices may act as a barrier for the adoption of cross-cutting technologies. A qualitative analysis of emerging technologies presented along with the detailed cost-effectiveness analysis of commercially available energy-efficient technologies can help to overcome the techno-economic barriers and achieve the implicit EE improvement target of the Swiss F&B sector

A bottom-up analysis of energy efficiency improvement and CO₂ emission reduction potentials for the swiss metals sector

The Swiss metals sector, comprised of manufacturing basic metals and fabricated metal products, is responsible for nearly 14% of total final energy (TFE) demand of the Swiss industry, making it one of the major energy consuming industrial sectors. This study investigates the current potential for energy efficiency (EE) improvement and CO2 abatement in the Swiss metals sector by means of bottom-up cost curves. Based on the comparison of Specific Energy Consumption for the processes applied in the Swiss metals sector with those of the best available techniques, the maximum technical EE potential for Swiss metals sector is estimated at 19%, while the economic EE potential is in the range of 11%–15%. The corresponding economic CO2 abatement potential is estimated at 6%. Among all measures, EE improvement of the rolling process was found to have the largest potential for TFE savings in the Swiss metals sector. The detailed insight into the EE gap and techno-economically feasible EE improvement solutions for the Swiss metals sector identified in this study will help to overcome the techno-economic barriers in implementing best practices in the high value-added metals sector

The evolution of energy efficiency in Switzerland in the period 2000-2016

Substantial improvement in traditional energy intensity indicator (4.5% p.a.) for Switzerland in the period 2000 to 2016 points towards strong decoupling of economic growth and energy demand. Since the improved energy intensity could be primarily driven by soaring value added, it is necessary to analyse 1) physical energy efficiency (EE) representing the contribution of technical progress to EE improvement and 2) the influence of other drivers of total final energy (TFE) demand. This work evaluates physical energy efficiency (EE) trends in Switzerland at various aggregation levels by applying the ODYSSEE energy efficiency index (ODEX). The ODEX methodology facilitates the estimation of physical (technical) EE trends based on subsector-specific physical activity indicators. Switzerland improved its physical EE by 1.4% p.a. in the period 2000–2016 with household being the fastest and industry being the slowest improving sector. Physical EE improvement was enhanced by structural change but it was partly offset by larger dwellings, more appliances per dwelling and physical activity growth. Although the combined indicator identifies Switzerland as the third best amongst the countries in ODYSEE database, individual sectors in Switzerland still need to increase their rate of EE improvement in order to meet the 2050 targets of Swiss Energy Strategy 2050

Corrigendum to “The evolution of energy efficiency in Switzerland in the period 2000–2016” [Energy 191 (2020)](S0360544219322212)(10.1016/j.energy.2019.116526)

The authors would like to clarify that after the acceptance of the article in the journal, we noticed that one of the supporting results presented in the paper could be misinterpreted. The estimation of rate at which GDP of Switzerland changed per year changes depending upon the currency in which the rate of change was measured (i.e. while converting from CHF to EUR). Although the change is trivial, we noticed that it might cause confusion to some readers. In order to avoid the confusion, we would like to add the following clarification to section 3.5 (for the number “4% p.a.") “Clarification: The average annual rate of growth of GDP is estimated at 2.2% when measured in the national currency (CHF). The difference to the value given in the first sentence of section 3.5 is a consequence of strengthening of the currency CHF against the EURO during 2000–2016”. The authors would like to apologise for any inconvenience caused

The evolution of energy efficiency in Switzerland in the period 2000–2016

Substantial improvement in traditional energy intensity indicator (4.5% p.a.) for Switzerland in the period 2000 to 2016 points towards strong decoupling of economic growth and energy demand. Since the improved energy intensity could be primarily driven by soaring value added, it is necessary to analyse 1) physical energy efficiency (EE) representing the contribution of technical progress to EE improvement and 2) the influence of other drivers of total final energy (TFE) demand. This work evaluates physical energy efficiency (EE) trends in Switzerland at various aggregation levels by applying the ODYSSEE energy efficiency index (ODEX). The ODEX methodology facilitates the estimation of physical (technical) EE trends based on subsector-specific physical activity indicators. Switzerland improved its physical EE by 1.4% p.a. in the period 2000–2016 with household being the fastest and industry being the slowest improving sector. Physical EE improvement was enhanced by structural change but it was partly offset by larger dwellings, more appliances per dwelling and physical activity growth. Although the combined indicator identifies Switzerland as the third best amongst the countries in ODYSEE database, individual sectors in Switzerland still need to increase their rate of EE improvement in order to meet the 2050 targets of Swiss Energy Strategy 2050

Corrigendum to "The evolution of energy efficiency in Switzerland in the period 2000-2016" [Energy 191 (2020)]

The authors would like to clarify that after the acceptance of the article in the journal, we noticed that one of the supporting results presented in the paper could be misinterpreted. The estimation of rate at which GDP of Switzerland changed per year changes depending upon the currency in which the rate of change was measured (i.e. while converting from CHF to EUR). Although the change is trivial, we noticed that it might cause confusion to some readers. In order to avoid the confusion, we would like to add the following clarification to section 3.5 (for the number “4% p.a.") “Clarification: The average annual rate of growth of GDP is estimated at 2.2% when measured in the national currency (CHF). The difference to the value given in the first sentence of section 3.5 is a consequence of strengthening of the currency CHF against the EURO during 2000–2016”. The authors would like to apologise for any inconvenience caused

A detailed review on current status of energy efficiency improvement in the Swiss industry sector

While quantitative methods for tracking the evolution of energy efficiency (EE) in industry do exist, these cannot always be directly applied, mainly due to lack of data on physical activity levels, as encountered in Switzerland. Therefore, a bottom-up method is developed and tested for estimating the sectoral physical activity levels in Switzerland. On this basis, sector-specific EE indices are determined. The results show that during the period 2009–2016, EE improved most in the paper sector (3.3% p.a.), followed by minerals (2.3% p.a.) and food (1.6% p.a.) sectors while the levels have remained approximately unchanged in chemical and metal sectors. Further-more, the annual change in final energy demand was decomposed into changes of physical production, price levels and EE. The analysis concluded that only the food sector performed well according to all performance indicators. The detailed analysis of the Swiss target agreements’ data has revealed major final energy savings in chemical and food sectors during the period 2000–2016. Among the different categories of EE measures, process related measures have proven to yield the highest energy savings across all sectors. The results indicate the successful implementation of EE measures in Swiss industry, favored by the relatively strict Swiss regulatory framework and its target agreement mechanism